Method of making thermally stable and crush resistant microporous glass catalyst supports

ABSTRACT

1. A METHOD FOR MAKING A LOW ALKALI-CONTAINING POROUS GLASS ARTICLE HAVING A HIGH THERMAL STABILITY COMPRISING: (A) HEATING A PHASE-SEPARABLE ALKALI-BOROSILICATE GLASSS TO A TEMPERATURE SUFFFICIENT TO SEPARATE THE GLASS INTO TWO PHASES, ONE OF WHICH IS A BORATE-RICH PHASE AND IS SOLUBLE IN AN AQUEOUS SOLUTION, (B) A FIRST LEACHING OF THE PHASE-SEPARATED GLASS WITH WATER FOR A TIME AND AT A TEMPERATURE SUFFICIENT TO REMOVE A MAJOR PORTION OF THE BORATE-RICH PHASE TO FORM A POROUS GLASS HIGH IN SILICA, (C) A SUBSEQUENT LEACHING OF THE PREVIOUSLY LEACHED POROUS GLASS WITH AN ACID FOR A TIME AND AT A TEM-   PERATURE SUFFICIENT TO REMOVE SUFFICIENT ALKALI AND BORATE NOT REMOVAL IN THE FIRST LEACHING TO PROVIDE A LOW ALKALI-BORATE CONTAINING MICROPOROUS GLASS STRUCTURE HAVING A HIGH THERMAL STABILITY.

Oct. 22, 1974 Filed Dec. 1, 1972 SAND J.J. METHOD OF MAKING THERMALLY STABLE AND CRUSH RESISTANT MICROPOROUS GLASS CATALYST SUPPORTS HAMMEL ETAL 5 Sheets-Sheet 1 Fiq l MAKE UP BATCH MIX BATCH BEADS MELT GLASS BEAD HEAT TREAT WATER L EACH AQUEOUS AC1 D LEACH YLEACH ATE BEADS AQUEOUS ACID RINSEDEIONI ZED WATER DRY POROUS GLASS BEADS APPLY CATALYST WATER SA LTS APPLICATIONS CATALYST SUPPORTED ON ESSENTIALLY POROUS SILSCA BEAD FIXED BED CATALYTIC REACTOR AUTQMQTI'VE CATALYTICMUFFLER FL-UTD BED CATALYTIC REACTOR PETROLEUM REFINER'.

0t.22, 1914 J J. HAMMEL ETAL 3,843,341

METHOD OF MAKING 'iHERMALLY STABLE AND CRUSH RESISTANT MICROPOROUS GLASS CATALYST SUPPORTS I Filed Dec. 1, 1972 5 Sheets-Sheet 2 WPEVOUMES VP 0 TH R Ay/TflBlLtTY v B(\;

- WAC KJ V 4 D k L RUH KXXXA/vw/ \A ALKALI METAL OXIDE B20 ct. 22, 1974 J. HAMMEL ETAL METHOD OF MAKING THERMALLY STABLE AND CRUSH RESISTANT MICROPOROUS GLASS CATALYST SUPPORTS Filed Dec. 1. 1972 5 Sheets-Sheet s :0 I2 I TlME. IN HOURS Oct. 22, 1974 M EL' ET AL 3,843,341

METHOD OF MAKING THERMALLY STABLE AND CRUSH RESISTANT MICROPOROUS GLASS CATALYST SUPPORTS Filed Dec. 1, 1972 5 Sheets-Sheet 4 GAUGE PRESSURE SWITCH LIJ SOLENOID VALVE NORM. OPEN -PANEL AUXILIARY CYLINDER CONNECTION @--A|R. SUPPLY TRIP D|sc TOGGL E SWITCH MmRoswwcH- ANVH. 1%

Get. 22, 1974 J.J. HAMMEL ET AL 3,843,341

METHOD OF MAKING THERMALLY STABLE AND CRUSH RESISTANT MICROPOROUS GLASS CATALYST SUPPORTS Filed Dec. 1, 1972 5 Sheets-Sheet 5 DUAL. RANGE PRESSURE RECORDER O-|O AND O-IOO POUNDS PER SQUARE INCH GAUGE PRESSURE SWITCH SET 10 POUNDS PER SQUARE INCH GAUGE SOLENOID VALVE moRmoPqw' f I f $1 Toscus SWITCH- SWITCH [20 v. .1 PHASE AUXILIARY K CONNECTION VALVE lx CYLIDER United States Patent Int. Cl. C03c 15/00 US. Cl. 65-22 20 Claims ABSTRACT OF THE DISCLOSURE Thermally stable, mechanically strong microporous glass articles with large pore volumes, surface areas, and varying pore sizes, and methods for making such articles are disclosed. In particle form, such as beads, the microporous glass articles are useful as catalyst supports in applications such as petroleum catalytic refiners and motor vehicle catalytic mufilers. The mechanical strength and the dimensional stability of the microporous glass articles at elevated temperatures can be improved if the articles are preshrunk, such as by brief exposure to high temperatures, before their intended use, and can be improved even further it treated with certain metal oxides.

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of the following applications: US. Pat. application Ser. No. 231,346, filed Mar. 2, 1972, now abandoned, and US. Pat, application Ser. No. 264,081, filed June 19, 1972, now abandoned.

BACKGROUND OF THE INVENTION Field of the invention This invention relates to high porosity glass articles, particularly microporous glass particles, having high crush strength and high thermal stability. This invention also relates to methods for making, as well as to glass compositions particularly suited to the methods of making such articles. In a particular aspect, this invention relates to a method of improving even further the crush strength and the dimensional stability of the porous glass articles at elevated temperatures.

Brief description of the prior art It is well known in the art to make a porous glass article by heat treating the glass to cause phase separation and then leaching the glass to extract the soluble phase. Such a procedure is disclosed in US. Pats. 2,106,744 and 2,221,709, both to Hood et al., which describe a method of making porous glass from an alkali-borosilicate glass by heat treatment of the glass to separate it into two phases, one of which is an insoluble phase being rich in silica, and the other is a soluble phase being rich in boric oxide and in alkali. The borate-rich phase is soluble in acid and may be leached out leaving the insoluble phase as a rigid cellular structure which maintains the shape of the initial glass. These porous silica structures have been suggested for use as catalyst supports. Other references which disclose the use of various porous glasses for use as catalyst supports are US. Pats. 2,461,841 to Nordberg;

2,480,672 to Plank; 2,834,738 to Vincent and 2,835,367

to Dowden et a1. Unfortunately, this utility is somewhat limited by the fact that high porosity structures up until the time of this invention have not been made with high mechanical strengths and thermal stabilities. For applica- 3,843,341 Patented Oct. 22, 1974 ICC tions such as fluid catalyst beds and motor vehicle catalyticmuffier's, poor mechanical strength and shrinkage ofthe catalyst support due to high temperature exposure is undesirable.

SUMMARY OF THE INVENTION In accordance with. this invention there is provided a method for making porous glass articles with enhanced crush strength and dimensional stability at elevated temperatures. The method involves phase separating a low silica-high, borate containing glass having the following composition:

into a silica-rich and a borate-rich phase. The phase-separated glass is then leached with water to remove slowly a sufficient quantity of the borate-rich phase to form a porous glass. The porous glass is then leached with an aqueous solution of acid to remove alkali and borate from the silica skeleton, to form a low alkali and borate microporous glass structure. After the acid leach, the porous glass is washed with deionized water to remove acid and any soluble phase remaining in the pores.

The crush strength and dimensional stability of the porous glass articles at elevated temperatures can be improved if the articles are slightly preshrunk before their intended use, e.g. for use as a catalyst support. The preshrinking operation can be accomplished by briefly exposing the porous glass particles to the maximum temperature they will be exposed to in use. For example, a /2 to 5-hour exposure to a temperature of 4001000 C. has been found to be satisfactory. When the porous glass articles of the invention are heated in such a fashion, the volume shrinkage amounts to about 5 to 20 percent of the original bead volume, and surprisingly, at a given temperature, most of the total observed shrinkage, i.e., 70 to percent, occurs during the first two hours or so of heat treatment. Since continued exposure to the elevated temperature results in only minimal additional shrinkage, the preshrunk porous glass beads can be used in a catalytic mufiler application with considerable assurance that additional shrinkage will not occur.

The dimensional stability of the porous glass articles at elevated temperatures can be improved even further if the porous glass is treated with tin oxide.

The porous glass articles of the invention have the For applications where dimensional stability at elevated temperatures and high crush strength are required, such as motor vehicle catalytic mufilers, porous glass particles can be made, in accordance with the invention, such that when the porous article is subjected to a temperature of 3 980 C. for 24 hours, it undergoes less than '25 percent volume shrinkage and loses less than 30 percent of its surface area. The crush'strength of such articles is at least 20 pounds per square inch gauge.

For applications where high pore volume and high pore size are required, the porous glass articles of the invention can be made with pore Volumes between 0.5 to 0.7 cubic centimeters per gram and average pore size diameters of from 200 to 1000 Angstrom units. The crush strength of such articles is about to 20 pounds per square inch gauge, and the dimensional stability of these high porosity articles is such that when they are subjected to a temperature of 760 C. for 24 hours, they undergo about to percent volume shrinkage.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a flow sheet depicting an overall process for making a porous glass bead product according to the invention.

FIG. 2 is a graph plotted on triangular coordinates showing the relative proportions of SiO B 0 and alkali metal oxide which must be used to prepare the microporous glass articles of the invention.

FIG. 3 are graphs showing the percent linear shrinkage, as a function of time, for various samples of microporous glass beads prepared in accordance with the invention and exposed to temperatures of 760-980 C. for the times shown on the graphs.

FIG. 4 shows a pneumatic pressure cylinder apparatus for measuring crush strengths of microporous glass beads of the invention.

FIG. 5 is a schematic diagram of the pneumatic pressure cylinder apparatus shown in FIG. 4.

DETAILED DESCRIPTION Referring to FIG. 1, an overall view of the invention is seen. The borosilicate glasses useful in this invention may be melted according to methods well known in the industry. Usually powdered raw materials containing sand, boric oxide, alkali metal oxides and, optionally, alumina are first batched, and then mixed and melted together. While it is preferred that the raw materials be present in forms which, when mixed and heated, most readily fuse to form a melt, the oxides may be present either in the free state or in the form of other suitable compounds. Examples of suitable compounds are alkali metal carbonates, borates and aluminates.

A glass having a composition prior to phase separation and leaching within the following limits is particularly suitable for use in the practice of this invention.

Percent by weight Broad Preferred range fange Ingredient:

S102 -50 38-46 B203 -55 40-52 R20 (where R=alkali metal) 5-15 8-12 A1103 0-4 0-0. 3

the thermal stability of the catalyst support as measured by the shrinkage of the article or measured by the loss of surface area due to a prolonged exposure to elevated temperatures, e.g. a 16 to 24-hour exposure at 850980 C. For high pore volumes, the silica content of the glass composition should be low, preferably about 38 to 45 percent, although the silica content should not be below 30 percent by weight because such glass. compositions, upon phase separation and leaching, yield porous glass structures which have relatively poor mechanical strength (crush strength).

The B 0 content is somewhat related to the SiO content and in general, as the SiO- content decreases, the B 0 content in the glass composition will increase. Preferably, the SiO /B O content is within the range of 1:1 to 1:l.3. The B 0 content should not exceed 55 percent by weight of the glass composition since the resultant microporous glass structure will have relatively poor crush strength. Also, the B 0 content should not be below 40 percent because such glasses are not readily leached with water and have too low pore volumes to be effective catalyst supports giving resultant high catalyst activity. In general, a lower SiO /B O ratio provides for a higher surface area and pore volume.

The alkali metal oxide is present as a flux to reduce the melting temperature of the glass. Lithium oxide, sodium oxide and potassium oxide, singly, or mixtures of any two or three may be employed, but sodium oxide is preferred. If the glass composition contains a lower portion of the alkali metal oxide as specified above, the fusion temperature of the glass may be too high for economical manufacture.

The alkali metal oxide content is also related to the mechanical strength of the resultant porous glass article. It has been found that either too high or too low an alkali metal oxide content results in a porous glass article with poor mechanical strength. Although not intending to be bound by any theory, it is believed that the alkali metal oxide plays an important part in phase separation and leaching. When present in the ranges set forth above, particularly within the preferred ranges, the alkali metal oxide is believed to make the mutually incompatible borate and silica phases somewhat more soluble in one another during the phase separation heat treatment. As a result, the coefiicients of thermal expansion of the borate and the silica phases are somewhat closer together than if there were a more complete separation of the phases. Therefore, when the glass is cooled down after a phaseseparating heat treatment, the difference in shrinkage between the borate phase and the silica phase is not nearly as great as it would be if there were a more complete separation. This reduces the shrinkage of the silica skeleton during the initial leach and minimizes the tendency towards stress cracking and mechanically weak beads.

On the other hand, when the alkali metal oxide content is too high, the silica and the borate phases become too soluble in one another during the heat treatment and as a result, when the borate phase is leached away from the silica skeleton, there is too much silica in the borate phase resulting in a silica-deficient skeleton which is mechanically weak and is easily crushed.

The following embodiment of the invention shows the effect of alkali metal oxide content on the crush strength of porous glass beads. The beads are prepared as generally described in Example I infra.

Composition:

S 40 45 46 48- 40 44 46 48 20 ll 8 4 1 0 19 22 2 0 1 Bead after leaching crumbled. 2 Beads had numerous fine cracks in surface.

As has been mentioned, one of the principal functions of the alkali metal oxide is to flux the glass melt, reducmg the melting temperature. It should be clear that other fiuxing agents well known in the art of melting and forming glass could also be used and are considered to be equivalent to the alkali metal oxides and within the scope of the glass compositions of the inventlon. Examples of suitable fluxing metal oxides, other than the alkali metal oxides which could be used in the practice of this invention include the alkaline earth metal oxides, particularly calcium and magnesium oxides and other metal oxides such as BaO, PbO, CdO, SnO and ZnO. The alkali metal oxides are clearly preferred, however, due to their excellent fiuxing ability and their ease in leaching from the silica skeleton.

FIG. 2 gives an idea of the relative proportion of SiO,, B 0 and alkali metal oxide in the glass compositions of the invention. The area inside the pentagon A B C D E represents the broader compositional ranges of the invention, and the area inside the hexagon F G H I I K represents the preferred glass composition of the invention.

Optionally, alumina, up to 4 percent by weight, can be introduced into the glass compositions. It is believed that the incorporation of alumina into a high-silica, low borate-containing glass (e.g. about 46-50 percent SiO 35-40 percent B 0 minimizes the danger of stress cracking of the silica skeleton during leaching. By stress cracking is meant that the outer or leached portion of the bead goes into tension due to shrinkage of the silica-rich skeleton, and the inner or unleached portion goes into compression. If the tension becomes too high and/or micro-flaws are present, cracks originating at the surface will develop. Alumina slows phase separation and produces smaller pores and therefore less concentration of stresses. This lowers the probability of producing a microcrack which will propagate under tension to a macrocrack. Also, the incorporation of alumina into the glass compositions results in porous glass articles with increased surface area. However, these high surface area glasses also suffer the greatest loss of surface area when the porous glasses are exposed to high temperatures. With the preferred glass compositions, containing about 38-46 percent by weight Si0 and 40-52 percent by weight B 0 alumina shows no particular advantage and is preferably excluded. In any event, greater than about 4 percent by weight alumina should not be used because glasses containing such high alumina contents are, in general, difficult to phase separate and to leach.

Usually in an analysis of the glass composition of the invention, about 0.15 to 0.3 percent A1 0 shows up. This is believed to be due to an alumina impurity in the silica. Thus, a calculated analysis will show no A1 0 an actual wet chemical analysis of the composition will show on occasion up to 0.3 percent A1 0 After a glass of the above composition has been melted, the glass is particulated. Particulation can be achieved directly from the glass melt or can be achieved by first forming the glass into a shape-retaining article and then mechanically breaking it. Particle size can be controlled by crushing or grinding, followed by sieving the particles through standard mesh screens. Alternatively, the glass can be particulated by directly quenching the glass melt with a suitable fluid. Examples of suitable fluids include air and liquids, such as water and oils. If the glass particles are formed directly from the glass melt as described above, they are usually in head form and no further shaping is necessary. However, if glass is particulated by mechanically breaking or direct quenching of the melt, further shaping or heading is necessary.

The beading operation consists of passing the irregularly shaped particles through an inclined rotating aluminalined tube furnace to spheroidize the particles putting them into bead form which is the most usable form for a catalyst support. The center portion of the tube furnace is at a temperature of about 9254100 C. to prevent sticking to the alumina tube, the particles can be mixed with boron nitride or carbon black. For example, one

part by weight of boron nitride to 74 parts by weight of glass will prevent sticking.

The bead size preferred for a porous catalyst support will vary depending upon the use to which the catalyst 18 tobe applied. For example, a fluid bed catalyst support should have an approximate head size diameter of from 0.10 to 0.30 millimeter (mm.), a fixed bed catalyst should have a head size diameter of approximately 1 to 2 mm., and catalyst support for use in a motor vehicle catalytic mufiler should have a bead size diameter of from about 2 to 4 mm. In general, it has been found that particles having a head size diameter from about 0.05 to 5.0 mm. are easily obtainable.

After the beads have been sized, they are phase separated. Phase separation can be carried out by heating the glass beads to a temperature of from about 420700 C. for a period of from 1 to 64 hours. The heat treatment, if properly carried out, will cause the glass to become more or less completely separated into two distinct phases, one of which is very rich in boric oxide and alkali and is soluble in water and acids, and the other phase is very rich in silica and is insoluble in water and acids (excluding, of course, hydrofluoric acid). The glass at this stage of the process may be characterized in most cases by a. bluish opalescence, due to the separation of the phases.

In carrying out the heat treatment, the viscosities and the volume fractions of the two separating phases are such that separation does not take place in the usual form of an emulsion or system of droplets dispersed in a second phase, but separation into a continuous thread-like structure of the soluble phase embedded in the insoluble phase occurs. The soluble phase, being of a continuous nature, can be entirely removed from the insoluble phase. When this is done, a rigid, porous structure of the original glass shape is left after the soluble phase is leached out.

The temperature and time for phase separation will depend principally on the pore size diameter and pore size distribution desired in the article. For example, in the heat treatment of porous glass beads, low temperature and short heat treatment times (eg. 420500 C. for l to 8 hours) will produce beads with average pore diameters in the 50 to 200 Angstrom range. These beads if properly leached and post treated will have excellent thermal stability and crush strength, making them particularly useful for catalytic mufilers. Longer times and higher temperatures (e.g. 8 to 24 hours at 580-650 C.) will produce pores in the 20 to 1000 Angstrom range. It is possible by carefully controlling the water leaching conditions as discussed below to obtain reasonably strong and thermally stable beads in the 600 to 1000 Angstrom range. Such beads are weaker than the beads with smaller pores and do not have the thermal stability. The crush strength of large pore size beads are on the order of 5 to 20 p.s.i.g. and the thermal stabilities are such that when the beads are exposed to. 760 C. for 24 hours, they undergo about a 10 to 20 percent volume shrinkage. Such beads are very useful however in applications where high thermal stability and crush strength are not required. For example, for use in crude oil refiners and low temperature fixed catalytic beds. In general, however, heat treating at a temperature higher than 700 C. is undesirable because of the tendency of the two phases to become miscible at these high temperatures, and the tendency of the glass beads to form stress cracks on leaching and to be thermally unstable, both excessively shrinking and losing a significant amount of surface area by prolonged exposure to elevated temperatures.

In using the preferred glass compositions of this invention, it has been found possible to heat treat at low temperatures, that is, from 460500 C., for short periods of time, such as 3 to 5 hours, and get a most efiicient phase separation. Upon subsequent leaching, the beads have high pore volumes, although somewhat small pore sizes, and are mechanically strong, being free of stress cracks. For

the broader ranges of glass compositions, other than the most preferred range, that is, glasses containing alumina and higher alkali content, the greatest porosity with accompanying absence of stress cracks and high mechanical strength can be obtained if the beads are heat treated for relatively long period of time, that is, from 16 to 64 hours, at relatively low temperatures, that is, from 450500 C. However, temperatures below 450 C. are undesirable because the glass viscosities are too high at these lower temperatures to permit any effective phase separation.

With certain glass compositions, it is possible to phase separate the glass by carefully cooling the glass immediately after forming. For example, after the glass heads have been formed either by spheroidizing particles in a rotating tube furnace or by forming the beads directly from a melt, the hot beads can be passed directly to a furnace and slowly cooled down through the annealing range to effect a phase separation.

After the glass beads have been heat treated and phase separated, they are cooled and subjected to an extraction process. The extraction process involves a first water leach followed by a second acid leach. In the water leach, the glass beads are immersed in a water bath to leach out the soluble borate-rich phase. The temperature of the leaching water bath should be about 80100 C., with about 90-l00 C. being preferred. As the temperature of the water bath falls below 80 C., there is less thorough extraction, and there must be a substantial increase in extraction time. In addition, the solubility of the borate-rich phase (alkali metal borate salts such as sodium pentaborate and boric acid) increases with temperature. At a water temperature of 90l00 C., the solubility of the borate-rich phase is about maximum. Complete solubility is important for recycling considerations which are discussed below. The time of leaching depends on the temperature of the bath and the size of the beads being treated. It has been found that a preferred temperature range of from about 90l00 C., a leaching time of from about 4 to 24 hours, preferably about to 12 hours, is suitable with beads having diameters of 2 to 4 millimeters. In addition, it has been found that greater crush strengths can be attained if the leaching is started cold since this has a tendency to reduce stress cracks, for example, less cracks will develop if the leaching is started at room temperature or slightly below and the temperature gradually raised to 90-100 C. over the period of about 2 to 4 hours, than if leaching is conducted for the entire 10 to 12 hours at 90 100 C.

The volume ratio of water to porous glass in the leaching should be about 2 to 8 volumes of water to 1 volume of glass. A low waterzglass ratio sloWs the leaching process, while a higher ratio serves no particular advantage. With porous glass articles having large pore sizes, i.e., on the order of 600 to 1000 Angstroms, it has been found desirable to leach with a metal borate solution such as sodium borate containing 100 to 400 grams per liter of Water. This significantly reduces stress cracking of the high pore size beads.

After the water leaching step, the water solution containing the soluble phase (hereafter called the leachate) is separated from the beads and transferred to a separator such as an evaporator, a cold trap collector, or the like to separate the Water from the borate salts which can be recycled and used in a subsequent glass melt. Also, the water can be collected and recycled for a subsequent leaching. Preferably, the hot leachate is transferred to a cold trap at -25 C. which causes about 80 percent of the borate salts to precipitate. The aqueous solution containing dissolved borate salts is recycled for subsequent leaching.

After the water leach, the glass beads are then transferred while still wet to an acid bath for a second leaching. Useful acids are dilute solutions, typically in the range of from .1 to 3 Normal solutions, of mineral acids, such as hydrochloric, sulfuric and nitric acid, or organic acids such as oxalic acid. The concentration of the acid and the time and temperature of the acid leaching will depend on the rate and the amount of alkali to be removed from the silica-rich skeleton. Higher normality acids, that is, from 2. to 3 Normal, are used when the preceding phase separation has not been complete with considerable portions of alkali and borate remaining within the silica skeleton. However, when the preceding phase separation has been complete with most of the borate and alkali located in channels throughout the silica skeleton, leaching in lower,

normality acids, that is, 0.1 to 0.3 Normal, are satisfactory. In general, an acid leach at a temperature of from about 30l00 C. for at least /2 hour, preferably about 2 to 4 hours, is satisfactory. It does not appear that the time and temperature of acid leaching have any measurable effect on the development of stress in the beads. Thus, long acid extractions at relatively high temperatures can be used. However, there appears to be no substantial advantage to acid leaching for a period of time greater than 4 hours.

The volume ratio acid to porous glass in the acid leaching should be about 1 to 8 volumes of acid to 1 volume of glass, and this ratio will vary somewhat with the normality of the acid being used. In general, the higher the normality of the acid, the lower the acid bead ratio.

The two-step water-acid leach enables the production of high porosity volume and high pore sized beads which have higher surface areas and better crush strengths and thermal stabilities than comparable beads leached with only water or acid. Although not intending to be bound by any theory, the reason Why the two-step water-acid leach may be so effective is because by first leaching with water, the extraction rate of borate-rich phase is slowed, and there is less extraction of the silica-rich phase. This produces less shrinkage of the silica phase, and the slower leaching rate gives the bead time to relieve some of the tension stresses developed, and leads to the production of a porous glass structure of high mechanical strength. The second leach with mineral acid removes a considerable amount of alkali metal oxide and borate from the silica skeleton not removed by the first water leach. Since alkali metal oxide and borate tend to reduce the softening temperature of the silica, their removal is believed to significantly improve the thermal stability of the resultantly leached porous glass structure.

Moreover, the two-step water-acid leach enables one to take the water leachate and recover the alkali metal borate salt and boric acid dissolved therein and recycle them for use in a subsequent glass melt. An acid leachate containing boric acid and alkali metal oxide could not be recycled as readily because of the contamination of the anion from the mineral acid. When common mineral acids, such as hydrochloric acid, surfuric acid and nitric acid are used, chlorine, sulfur dioxide and various noxious nitrogen gases would be given off during the water removal and glass remelting steps. This, of course, would pose serious pollution problems.

By recycling the boraterich phase over and over again, it is possible to make the porous articles of the invention containing greater than 96 percent by weight silica starting essentially with only sand. Little energy i required for melting, and there is nopollution or effluent problem due to the discharge of the borate salts. Further, raw material costs are significantly minimized.

After the acid treatment, the glass is washed to remove all traces of the soluble phase which are yet remaining and also any soluble impurities, such as iron, which may have been acted on by the acid. Washing may be accomplished by immersing the glass beads for about 1 to 4 hours in running tap, or preferably deionized water, in such a manner as to expose all the pores of the glass to the action of the water. A washing in deionized water is preferred because the resultant beads are found to have better thermal stability than beads Washed with tap water. In other words, it has been found that beads which have been washed with deionized water undergo less shrinkage and surface area loss on long-term thermal exposure than do beads which have been washed'with tap .water. After washing, the beads are usually air dried in an air-circulating oven usually at 80-l00 C. to remove water and then dried'at 760 C. for 1 hour to remove chemically bound water.

The microporous glass beads upon visual observation are seen to retain the original shape of the solid bead.

,Upon electron-microscopic observation, the beads can be seen to be extremely porous, having interconnected pores throughout the bead.

Upon elemental analysis, the beads have the following composition:

1 Shows up as an impurity even though no A1203 added to the batch ingredients.

The microporous heads have high porosity and surface area as measured by nitrogen adsorption according to the method of, Braunauer, Emmett and Teller usmg an automated commercial apparatus. For a discussion of this method, familiarly called the BET method, see S. Braunauer, The Adsorption of Gases and Vapors, Vol. 1, Princeton University Press, 1943. Accordingly, the pore volume is at least 0.35 cubic centimeters per gram, and often higher, from about 0.40 to 0.70 cubic centimeters per gram (cc./g.), and the surface area of the porous beads is at least 100 square meters per gram, and usually between 200 to 400 square meters per gram (m. /g.). Pore size diameter, as determined by electron microscopy, is on the order of 50 to 1000 Angstrom units, depending on the phase-separating heat treatment as discussed above. It should be noted at this point that the pore size diameters are average values; the pore sizes being averaged over a fairly narrow distribution. It has been found for a given average pore size 50 to 60 percent of the pores are within :20 percent of the given value. For example, for an average pore size of 100 Angstroms, 50 to 60 percent of the pores will have a diameter within the range of 80-120 Angstroms.

Besides high porosity and surface area, the microporous glass beads of this invention have surprisingly good mechanical and thermal properties as measured by crush strength and thermal stability at 980 C.

The crush strength of the microporous glass beads of this invention is described as the air pressure in pounds per square inch gauge required to break the catalyst under specified test conditions.

Briefly, the test for crush strength involves taking a representative number of beads, preferably about 40 beads of approximately the same dimensions, and placing each head in turn on the anvil of a pressure cylinder device, as shown in FIG. 4 and crushing the bead by an airdriven piston. The air pressure required is accurately gauged and converted to pounds per square inch gauge by means of a previously prepared calibration curve. The average value of the converted pressure readings are reported as the crush strength.

10 In measuring crush strengths, the following apparatus and technique should be used:

APPARATUS '(l) (a) Blending apparatus.Any approved blending apparatus appropriate to the size of sample being mixed is satisfactory. A blender is recommended for samples of one gallon or less, a splitter for one to two gallon samples. and a drum roller for larger samples.

(b) Micrometer.

(c) Mufile furnace, equipped with temperature-measuring and controlling devices.

(d) Pneumatic pressure cylinder apparatus, conforming to the design of FIG. 4 and having electrical and air circuitry as indicated in FIG. 5.

(e) Tweezers. SAMPLING (2) Sample the catalyst by any approved procedure to obtain a representative composite. Usually at least a one gallon sample is required for test normally applied to catalyst support.

PREPARATION OF SAMPLE (3) (a) Prior to analysis, mix the sample thoroughly by any approved procedure, and dry it in a mu-file furnace for three hours at 250 F. unless other conditions are specified. Cool in a desiccator containing Drierite.

(b) Using a micrometer, measure the diameter of ten randomly chosen whole particles, and record the maximum, minimum and average values.

(0) Select a representative number of particles, preferably about 40, of approximately average diameter for testing.

PREPARATION OF APPARATUS (4) (a) Turn on the main line power supply, and the main line air supply valve. Adjust the needle valve on the air supply line so that 8.6 seconds are required for the air pressure to reach 25 pounds, or 17.6 seconds to reach 50 pounds, as indicated on the recorder.

(b) Insert an anvil of the proper height in the opening in the bottom of the apparatus. Proper anvil height depends upon the diameter of the particles being tested, and must be such that the descending piston will trip the microswitch and release the air pressure, when the particle is crushed. If the correct anvil is used, no adjustment of the microswitch position should be necessary.

(0) If necessary, perform trial runs on several particles according to the procedure in Section 6 (b) and (c), to establish the requisite height of the anvil. If an anvil of the desired height is not obtainable, adjust the position of the microswitch in relation to the available anvil, so that the switch will be tripped when the particle is crushed.

CALIBRATION (5) Calibrate the air pressure recorder by any convenient procedure. The following procedure is recommended, but not mandatory. Insert a stout metal rod through the anvil opening, allowing the bottom tip of the rod to contact the pan of a platform balance. Align the rod so that the piston touches it. Turn on the power and air supply to the apparatus and apply selected air pressures to the piston. Record each applied pressure reading indicated on the recorder, and the corresponding weight reading indicated on the balance. Plot a calibration curve of recorder readings against observed Weights.

l PROCEDURE (6) (a) Perform the measuring procedures in Section 3 (b) through (c) and prepare the apparatus as instructed in Section 4.

(b) Using tweezers, place a dried particle on the anvil. Lower the piston manually so that it touches the tweezers.

Carefully remove the tweezers and allow the piston to rest on the particle.

(c) Turn on the toggle switch and allow the piston to crush the particle. Turn off the toggle switch immediately to vent the air flow, and manually raise the piston. Clean the anvil and piston with a brush before testing the next particle.

((1) Process each of the particles in turn according to the procedure in Paragraphs (a) through (c).

t CALCULATION (7) (a) Convert each of the air pressure readings (preferably 40 readings) on the recorder chart to pounds by means of the previously prepared calibration curve.

(b) Average all the converted pressure readings and report the average value as the crush strength.

As measured by the above-described test, the crush strength of glass beads prepared according to this invention is at least 20' pounds per square inch gauge (p.s.i.g.) and are usually greater than 30 p.s.i.g. for beads having average pore size diameter within the range of 50 to 200 Angstrom units. With beads having larger average pore sizes, i.e., on the order of 200 to 1000 Angstrom units, crush strengths are somewhat lower, being on the order of to 20 p.s.i.g. l

A measure of the thermal stability of the beads can be attained by exposing previously dried beads to a temperature of 980 C. for 24 hours in a muflle furnace and measuring the loss of surface area and volume after the beads have cooled. The loss in volume of the beads is referred to as the volume shrinkage. Accordingly, the microporous glass beads of the invention have pore sizes on the order of 30 to 200 Angstroms when subjected to the above treatment, lose less than 30 percent of their original surface, and undergo less than 25 percent loss of volume (volume shrinkage). Larger pore size beads, i.e., 200 to 1000 Angstrom beads, are not quite as thermally stable and when subjected to 760 C. for 24 hours, they undergo about to percent volume shrinkage.

The crush strength and thermal stabilities of the porous glass articles of the invention can be increased by slightly shrinking the beads. Since the shrinking would usually be conducted before the porous articles are used, for example, as a catalyst support, the shrinking will hereinafter be referred to as preshrinking.

The preshrinking operation is conducted by taking the porous articles, for example, in bead form, and briefly exposing them to an elevated temperature, i.e., a temperature of 4001000 C., and preferably a temperature of about 800l 000 C. By suitably selecting temperature and time of exposure, the beads can be preshunk to at least 70 percent, and preferably to greater than 90 percent, of the total shrinkage that they will undergo during their intended use as a catalyst support without excess loss of surface area or pore volume. In other words, after the beads have been suitably preshrunk, they Will undergo no more than 10 percent volume shrinkage during the period of their intended use. The volume shrinkage is determined by measuring the loss of compacted bulk volume. Somewhat surprisingly, it has been found that the necessary preshrinkage can be accomplished by only a brief exposure at the required temperature, i.e., an exposure of up to 5 hours, and preferably less than 2 hours.

When porous glass particles are to be used as catalyst supports in higher temperature applications, for example, in a catalytic mufiler which is exposed to temperatures of 8001000 C., the preshrinking should be conducted a. the higher temperatures, that is, at about 9001000 C., in order to get the required dimensional stability at this high a use temperature. However, where lower temperature applications are envisioned, for example, in a catalytic cracker which operates at temperatures of 400500 C., a brief exposure within this temperature range will produce suflicient preshrinkage to make the particles dimensionally stable at this lower use temperature. Therefore, a preshrinkage temperature range of 4001000 C. is recommended, depending on the temperature that catalyst particles will be exposed to in use. An upper temperature limit of 1000 C. is recommended because at higher temperatures the micropores will tend to collapse, excessively reducing the surface area and pore volume. A lower temperature of 400 C. is recommended because at lower temperatures too little shrinkage occurs in a reasonable amount of time in order for the preshrinking operation to be practical.

Although not intending to be bound by any theory, the reason why it is believed that the microporous glass beads of this invention can be successfully preshrunk by only a brief exposure at high temperature is because of the particular physical properties of the beads. The microporous beads of this invention have very low alkali and borate content, which is due to the careful removal of residual soda and most of the borate from the silica skeleton. This creates tiny holes in the silica skeleton, which are active sites for hydroxyl adsorption. Chemically bound water will come off at relatively low temperature (e.g. 400760 C.) as evidenced by loss of weight, and will leave atomic-size or slightly larger holes. A brief exposure to medium or high temperatures will collapse these skeletal holes, resulting in a sharp initial linear shrinkage. After the initial shrinkage, additional shrinking will proceed much slower due to a collapsing of the main interconnecting pores. To collapse these main interconnecting pores, a very high temperature, somewhere near the annealing point of a 96 to 99 percent silica material will be required. Thus, further heat treatment will result in only minimal shrinkage.

After the microporous beads have been preshrunk by a brief exposure to an elevated temperature, e.g. 800- 1000 C. for 1 hour, the physical properties of the heads have not changed appreciably. The volume shrinkage of the beads is about 5 to 20 percent based on the original bead volume, the beads have lost about 10 to 25 percent of their original surface area, and about 5 to 20 percent of their original pore volume. The crush strength of the beads is increased to about 30 to p.s.i.g., and the pore size is slightly increased. The bulk density of the beads increased from about 0.60 to 0.70 grams per cubic centimeter (g./cc.).

The initial loss of surface area actually works as an advantage and provides for a more efficient use of catalysts. In the catalyst treating operation, the porous beads are impregnated with a catalyst solution and the solvent evaporated to deposit the catalyst in the pores of the porous glass support. The initial loss of surface area is due to the collapsing of the tiny holes in the silica skeleton. These tiny holes, although contributing to the surface area is measured by nitrogen adsorption, contribute little to resultant catalytic activity since they quickly collapse at elevated temperatures. Thus, any catalyst which is present in these pores will either be encapsulated within the silica skeleton or at least be deactivated after a short period of high temperature catalytic operation. This, of course, results in a waste of expensive catalyst, e.g. noble metal. If, however, the microporous glass bead-catalyst supports are first subjected to a preshrinking heat treatment, the tiny micropores will be closed off to any catalyst solution and the catalyst will deposit only on the main interconnecting micropores.

The dimensional stability of the beads at elevated temperatures is significantly increased by preshrinking. Thus, beads which have been preshrunk in accordance with the practice of this invention are 3 to 4 times more dimensionally stable than non-shrunk beads as measured by comparing decrease in volume shrinkage at 98 C. for 24 hours.

A comparison of typical physical properties of the preshrunken beads and non-shrunken beads is reported in Table I below.

TABLE I [Comparison of physical properties of preshrunk and non-shrunk beads] Preshrunk (980 C. for 1 hour) Non-shrunk Percent by weight Percent by weight Component Broad range Preferred range Component Broad range Preferred range Elemental analysis SiOz At least 96 97-00 SiOz At least 96 96-99 B20; Less than 4 1-3 B20! Less than 4 1-3 N azO Less than 05 00. 03 NazO Less than 0.05- 0-0. 03

A120 Less than 0.4. A120: Less than 0.4- 0 Particle size Somewhat less than 2 to 4 millimeters 2 to 4 millimeters Pore volume Average pore size. Surface area Volume shrinkage after 24 hours at 980 0..... Crush strength 40 50 to 1,000 Angstroms 0.25 to 0.5 cubic centimeters per gram 100 to 350 square meters per gram 3 to percent (pcre size 50 to 200 Angstroms) to 70 pounds per square inch gauge (pore size 50 to 200 Angstrom 0.35 to 0.7 cubic centimeters per gram 50 to 1,000 Angstroms 150 to 4.00 square meters per gram 25 percent (pore size 50 to 200 Angstroms) pounds per square inch gauge (pore to 200 Angstroms) As has been mentioned above, the porous glass articles of the invention, particularly in particle form, have utility as catalyst supports. Catalysts can be impregnated into the porous particles by soaking the particles in solutions of the catalyst or vapor depositing the catalyst in the pores of the particles. Thus, for example, to deposit refractory metal oxides such as tin oxide or noble metals such as platinum or palladium or metal oxides such as TiO V 0 Cr O FeO, CoO, NiO or Cut), a solution of the metal salt which can be decomposed by heat to the metal oxide or noble metal can be used to impregnate the porous particles. Examples of such salts are metal ..-chl0rides, nitrates, acetylacetonates and carbonyls. In the case where it is desired to have the catalyst in the metallic state, the deposited metal oxide can be subsequently reduced by passing a stream of hydrogen gas over the support.

Tin oxide (SnO is a particularly desirable metal oxide to deposit on the porous glass articles of the invention. Tin oxide has been found to provide additional thermal stability to the porous glass bead. This is somewhat surprising in that other metal oxides such as A1 0 Cr O and ZrO do not provide analogous results.

The amount of tin oxide deposited within the pores should be about 0.5 to 10 percent, preferably about 1 to 5 percent by weight. The amount of tin to be deposited can easily be determined by knowing the pore volume of the particles and by adjusting the concentration of the treating solution. Thus, for example, to deposit about 1.5 percent by weight SnO in the pores of a porous glass article having a pore volume of about 0.5 cc./g., the particles should be soaked for about 15 minutes in a solution containing about 150 grams of SnCl '5H O per liter of water. After soaking, the beads should be dried at 100 C. to remove water and then calcined to convert the tin chloride to tin oxide.

It should also be noted that in soaking the porous glass particles of the invention in metal salt solution, it is preferable that the particles be preshrunk before soaking. Preshrinking, as has been mentioned above, strengthens the beads. The beads in soaking quickly absorb solution due to capillary action, and entrap significant quantities of air within the particles. This builds up pressures, and if great enough, will fracture the beads if they are not strong enough.

EXAMPLE I The following example shows on a laboratory scale the preferred embodiment of the invention.

A glass melt was obtained by thoroughly mixing and melting in a crucible at 1250 C. 1000 grams of silica,

2168 grams of boric acid and 470 grams of sodium carbonate. The melt was stirred and held for one hour at 1250 C. The temperature was then lowered to 1025 C. and the melt stirred and fined for an additional 3 hours. The calculated composition of the glass expressed as the oxides of the glass-making ingredients was as follows:

Ingredient: Percent by weight SiO2 40 The molten glass was particulated to a frit by blowing a cold stream of air on the glass as it was poured from the crucible. The frit was sieved, and the fraction passing through a No. 5 US. standard sieve and not through a No. 10 US. standard sieve was collected. The larger fragments collected on a No. 5 sieve were passed through a jaw crusher for very large particles and a roll crusher for smaller particles. Again, the fraction between the No. 5 and No. 10 sieve were collected.

The particles collected from sieving (about 2 to 4 millimeters in size) were headed to spherical shapes in an inclined rotating tube furnace Type 54233, manufactured by Lindbergh Company, a Division of Sola Basic Industries. The center portion of the tube furnace was at approximately 1050" C. To prevent sticking of the glass to the alumina tube, the glass particles were mixed with boron nitride in a ratio of one part by weight of boron nitride to 74 parts by weight of glass. The mixture was fed into the tube furnace at one end by means of a screw feeder. No sticking was encountered and better than 98 percent of the glass particles were beaded. After beading, the particles were again sieved and shaken to remove boron nitride and to separate the over and undersized beads.

The beads were then placed in a ceramic tray and heat treated at 480 C. for 5 hours. The beads were now separated into silica-rich and borate-rich phases.

After heat treating, the beads: were cooled to about room temperature and charged to a reflux flask containing tap water at room temperature. The volume of water to beads was about 5 to 1. The temperature was raised over the period of 4 hours to C., and this temperature maintained for 12 hours to complete leaching. After leaching the beads were separated from the leachate and 15 the leachate passed through to a cold trap at room temperature where about 80 percent of the borate salts precipitated from solution. The salts were dried and recycled for use in a subsequent melt and the water solution containing the unprecipitated borate was recycled for use in subsequent leaching.

The beads which were separated from the leachate were then transferred to a reflux flask containing 0.3 Normal hydrochloric acid at 95 C. for acid leaching. The volume of acid to beads was about to 1 and leaching was conducted for about 5 hours. After leaching the beads were removed from the acid bath and rinsed in deionized water to remove hydrochloric acid and any soluble phase remaining in the pores of the beads. The beads were then dried in an air-circulating oven at 85 C. to remove excess water and then heated to 760 C. for 1 hour to remove chemically bound water. The physical properties of the beads were measured and are reported in Table II below:

16 EXAMPLES II TO v11 To show the effect that glass composition, particularly the SiO; and the B 0 content, has on pore volumes and crush strengths of porous glass beads, the following examples are presented:

Porous glass beads having Si0 contents ranging from to 70 percent, and B 0 contents ranging from 20 to percent, were prepared as generally described in the method of Example I, that is, silica, boric acid, sodium carbonate and alumina were thoroughly mixed and melted for about 6 to 7 hours at temperatures between 1250 to 1450 C.; higher temperatures being used to melt the higher silica-containing glasses. The glass melt was fritted by pouring it into water, and the frit sieved to collect the desired size particles. The particles were spheroidized in an inclined rotating tube furnace as described in Example I. The resultant beads were then heat treated, leached and rinsed as generally described in Example I. The results of the experiments are shown in Table III below.

TAB LE III [Effect of S101 and B20; Content on Pore Volumes, Surface Areas and Crush Strengths of Porous Glass Beads] Example Number II III IV V VI VII Glass composition (percent by weight):

2- 66. 2 55. 0 45. 0 40.1 30. 7 13203... 22. 8 24. 5 33. 5 43. 3 50.1 59. 1 82 7. 2 7. 3 10. o 7. 7 9. 9 10. 2 Al Os.. 2. 0 1. 5 4. 0 0.14 Bead size diameter (in millimeters) 2-4 2 1-2 1-4 2 2-4 Heat treatment (time in hours/ 0.)- 4/600 4/560 24/550 5/500 4/480 4/460 Lea (N /t e in h u sl 3/27/95 3 30 5 1 e4 95 1 64 95 0 2 2 32 0 Bead composition after leaching (perceh tz hyweig hti /9 I S102. 96. 3 96. 1 97. 1 97. 5 B103. 3. 42 3. 48 2. 65 2. 25 NazO 0. 06 0. 04 0. 04 0. 04 A1 03 0. 15 0. 31 0. 25 0. 25 u ace a ea ile). 162 152 199 230 Pore volume (cc./g.) 0.12 0.15 0. 29 0. 47 Crush strength (p.s.1.g.) s0 23 (crack) 30 16-hour exposure to 850 C. surface area (mi/g.) 93 145 152 Percent volume shrinkage 10 15 19 18 a Water leach for 16 hours at C.

TABLE II [Physical properties of porous glass beads prepared according to Example I] Component Percent by weight Elemental analysis SiO; 98. 18

BzOa 1. 62

NazO 0. 04

A1203 '0. 18 Particle size 2-4 millimeters Compacted bulk dens1ty 0.62 grams per cubic centimeter (g./cc.) Pore volume 0.59 cubic centimeters per gram (cc./g.) Average pore size. -120 Angstrom units (A.) Surface area 230 square meters per gram (ml/g.)

Crush strength .I 37 pounds per square inch gauge (p.s.i.g.) (average 20 samples). After 1 hour at 980 0.:

Surface area 193 mJ/g. Loss of surface area. 12% Volume shn'nkage 16% Pore volume 0.48 cc./g. Compacted bulk den 0.69 g./cc.

Crush strength... 57 p.s.i.g. (average of 20 samples) After 24 hours at 980 Surface area mfi/g. Loss of surface area (additional) 12% Volume shrinkage (additional) 6% Pore volume 0.40 cc./g. Crush strength 72 p.s.i.g.

*Alzoa shows up in the analysis even though no A1203 in calculated glass composition, probably due to alumina impurity in SiO b Beads very weak and broke up on leaching.

EXAMPLES VIII TO XI To show the effect that alumina in the glass composition has on the surface area, thermal stability and leaching rate of porous glass beads of the invention, the following examples are presented. Leaching rate is determined by measuring in recession of the borate-rich phase as a function of leaching time. The recession is visible because of dilterence in refractive index between leached and unleached portions of the bead.

TABLE IV [Effects of A110: content on leaching rate, surface area and thermal stability of porous glass beads] Example number VIII IX X XI Composition:

a. 45 45 45 45 B10- 42 42. 5 45 46 aa- 2 9 r a. i

Heat treatment: Temp. C 520 5004 500 500 Time in hours. 0 1 N H34 w 32: 8 8

- o ater Water W ter 1st Leach (time in hours/temp. C.) (24/95) (1 6 m) (1 6 /95) (16795) 2nd Leach (time in hours/temp. C.) I 0 1 0 1 Surface area (mfi/g.) 370 302 258 161 Thermal stabihty surface area (mJ/g.) after exposure to 850 C. for 16 hours 199 193: 179 122 Percent surface area left after exposure- 54 64 69 74 Leaching rate (mm/hours) 0. 05 0. l 0. 2 0. 25

Leach started in cold water at C. and temperature slowly raised over 1% hours to 95 C.

EXAMPLES XII TO XIV EXAMPLE XV The following examples show how beads, made with the preferred glass compositions of the invention, respond to varying times and temperatures of heat treatment. An analyzed glass composition containing 40.7% SiO 48.9% B 0 9.9% Na O and 0.21% A1 0 was prepared as generally described in the method of Example I. The glass was particulated as generally described in Example I into beads having a diameter of about 2 to 4 millimeters. The beads were then heat treated for various times and temperatures as shown in Table V below. After heat treating, the beads were leached first in tap water at 95 C. for 16 hours, followed by an acid lead in 0.3 N hydrochloric acid for 5 hours at 95 C. After the acid leach, the beads were rinsed with flowing deionized water. The beads were air dried and examined under a microscope for cracks and pore size. Crush strength measurements were taken, and the beads were then shrunk by a 2-hour exposure to 980 C. After shrinking, the crushstrength was remeasured and the amount of shrinkage determined. The thermal stahility of the preshrunk beads was then determined by exposing them to 980 C. for 16 hours and measuring the shrinkage and the loss of surface area. The results are presented in Table V below.

TABLE V [Effects 0! time and temperature of heat treatment on crush strength and thermal stability of porous glass beads] Example number XII XIII XIV 3/460 3/480 3/500 Heat treatment (time in hours/temp. C.). 5/460 5/480 5/500 8/460 8/4 8/500 16/460 16/480 10/500 3 2 it Cra ks -in 50 heads 1 c 8 4 23 3 40 i2? 328 16 0 sh stren th .s.l.

m g (p g) 24.1 23.0 16.8 22. 4 10 11. 0 Preshrinking at 980 C. for 2 hours: I m m 16 Shrinkage (volume percent) 17 16 18 16 17 29 16 26 54 11.0 32.2:3 Crush stren th .s.i 29.5 4

g (p g) 41.7 48.4 52.0 40.2 70 120 High temperature exposure at 980 C. (or

hours:

8.3 .5 9.5 Shrinkage (volume percent) 9.4 14 19.5 9.5 15.5 35 14.3 36.5 2.5 173 167 126 Surface area (mJ/g.) 155 159 71 L 158 64 0 152 0 0 Component: Percent by weight S10 45.4 B 0 42.2. N320 A1 0 3.8

The molten glass was particulated and beaded into spherical shape as described in Example I to give beads having a diameter of about 1 to 2 millimeters in size. The beads were heat treated at 500 C. for 64 hours. After heat treating, the beads were cooled to room temperature and leached with hot tap water at C. for

24 hours. A portion of the beads were set aside, washed to remove any soluble phase remaining in the pores and then dried in an air-circulating oven at 85 C. The composition, pore volume, surface area, crush strength and thermal stability of these beads were measured, and the results reported in Table VI below.

The remaining portion of the beads were transferred to a reflux flask containing 1 Normal hydrochloric acid and leached at C. for 24 hours. After acid leaching, the beads were removed from the acid and rinsed in water to remove hydrochloric acid and any soluble phase remaining in the pores of the beads. The beads were dried in an air-circulating oven at 85 C. The physical properties of these beads are reported in Table VI below.

A second glass composition, similar to the one described immediately above, and having the following composition:

Component: Percent by weight SiO 45.0 B 0 43.3 N320 7-7 A1 0 4.0

. T4 I. [Physical properties ot p orou's glassbeadsjrprepared"according to Example XV] Water plus acid v. Water leach leach Aeld leach I 1 ,....Percent Percent .Percent Compoby Compoby Compoby nent weight pent weight nent welght Elem nt lanai sis of orous beads SiO 91.7 S10 96.6 $10, 96.5'

e a y p B 3.1 B26: 3.16 B20: 3.25 N810 0.85 N320 0. 01 N320 0.05 A1103 3. 8 A1203 0. 22 Alzoa 0. Particle size 1-2 mm. 1-2 mm. 1-2 mm.

0 38 ccJg 0 45 ce./g. 0.47 ceJg. Surface area 234 rnfl/g 253 mJ/g 215 mfilg. Surface area after 16 hours at 850 C. 124 mJ/g 173 mfl/g 110 mJ/g. Loss oisurfaee area .6% 49 Crush strength 22 p.s.i.g. 24 psi g 16 p.s.i.g.

EXAMPLES XVI TO XXI Exam le umber The following examples show how the rinsing of the v p n glass beads after acid leaching with deionized water en- Component XXII XXIII XXIV XX XX I hances the thermal stability of the beads, as compared by 45,61 45.24 41.1 go. 1 45.9 45.57 48.84 48.4 0.1 44. nnsmg with tap Water a. 22 0.22 0.15 0.14 0.14 The glass beads were prepared by the method gen- M6 1087 mo 99 M erally described in Example I. The analyzed glass composition was 46.1% SiO 45.8% B 0 and 8.0% Na O. Glass beads having a diameter of about 1 to 2 millimeters were prepared by fritting and beading and the beads heat treated at 480 C. for 5 hours. The heat treated beads were cooled and leached first in hot tap 'water at 95 C. for 16 hours and then in 0.3 N HCl at 95 C. for 6 hours. The beads were then rinsed in either flowing tap water or deionized water at 95 C. for the times listed in Table VII below. The beads were then air dried and exposed to a temperature of 950 C. for 16 hours in a mufiie furnace. The surface area was measured before and after the heat treatment and the results are presented in Table VII below.

The glass was particulated, sized and beaded as generally described in Example I. The beads were then heat treated at various times and temperatures to cause phase separation. After heat treating, the beads were cooled to room temperature and leached using hot tap water. The beads were then leached with hot hydrochloric acid, after which they were rinsed in deionized water to remove hydrochloric acid and any soluble phase remaining in the pores of the beads. The beads were then air dried at 95 C. The various heat treatment and leaching cycles are reported immediately below as are the physical prop-' erties of the various beads.

Heat treatment Water leach Acid leach,

N of 1101/ Bead size Pore Surface Crush Time in Temp., Time in Temp, time in hours diameter volume area strength Example number hours C. ours C. temp. 0. (mm) (ee./g.) (mi/g.) (p.s.i.g

8 500 16 95 0. l/l6/95 2-4 0. 326 19 64 500 24 95 0. 1/ 7/ 95 2-4 0. 45 246 21 5 480 16 95 3/5/95 5 0. 60 252 25 5 480 16 95 3/5/95 4 O. 58 223 37. 7 5 480 16 95 3/5/95 4 0. 47 179 38. 7

TABLE VII [Experiments on enhancing thermal st]ability by using a deionized water rinse Thermal stability,

16-hour exposure at 950 0.,surfaee area (ml/g.)

Example No. Rinse Before After XVI. 209 119 209 3 135 209 137 209. r. 62 209 EXAMPLES XXII TO v The following examples show the preshrinking facet of this invention. 1

The following glass compositions were prepared generally according to the method Qf 52 9 The microporous glass beads were then shrunk exposing them to elevated temperatures for various periods of time as reported in Table VIII below. The linear TABLE VIII Linear shrinkage Loss of surface area,

Successive heat treatment AD/D (percent) A 8/5 (percent) oms;

s reng Example number Temp. C.) Time (hrs) Additional Total Additional Total (p.s.i.g.)

XXII 510 1 3. 7

XXIII .7 850 1 3.1

XXIV 760 1 2. 9

XXV ..:..n 760 1 2. 8

XXVI 980 1 6. 85

XXVI 760 1 4. 5

FIG. 3 shows gaphically the percentage of the linear shrinkage as a function of time for Examples XXIV and XXVI.

The following examples show the depositing of various metal oxides and noble metals onto porous glass beads of the invention.

EXAMPLE XXVII One hundred and sixty (160) grams of A1(NO3)3 dissolved in one liter of water was used to soak about 500 grams of heads prepared as described in Example I. The beads had a pore volume of about 0.54 cc./g., and soaking was conducted for about 15 minutes after which time the beads were vacuum dried on a Biichner funnel to remove excess soaking solution. The beads were then dried at 100 C. to remove water and then calcined at 700 C. for 2 hours to convert the aluminum nitrate to A1 0 Upon analysis, the beads were found to have about 1 percent A1 0 deposited in the pores. The A1 0 coated beads could then be used as a cracking catalyst.

EXAMPLES XXVIII TO XXXII In an analogous manner to the method of Example XXVII, porous glass beads such as described in Example I were treated with Cr O ZrO SnO mixed Cr O -CuO and mixed platinum-palladium, respectively. The treating solutions were:

Example No. Treating solution XXVIII 125 grams of CrCla-fiHzO/liter of water.

XXIX 150 grams of ZrOClrSHzO/liter of water.

XXX-.. 67 grams of 01101 and 150 grams of CICla-fiHzO/Z liters of water. XXXI- 6.7 grams of H014 and 5.9 grams of PdC12/2 liters of water. XXXII. 147 grams of SnCl4-5H 0/liter of water.

supported catalyst was used as an oxidation catalyst and for hydrocracking.

EXAMPLE XXXIII To show the thermal stabilizing effect of depositing tin oxide on the porous glass article of the invention, the following experiment was conducted:

A glass composition containing:

Ingredient: Percent by weight SiO 41.1 B 0 48.4 Na -O 10 A1 0 15 was melted, particulated, sized and headed as generally described in Example I. The beads which had a diameter of about A; inch were heat treated at 480 C. for 5 hours, cooled and leached first in hot water for 16 hours at C. and then in hot acid 0.3 N HCl at 95 C. for 5 hours. The beads were rinsed in deionized water and air dried. The beads were preshrunk by a 2-hour exposure to 980 C. The beads had the following physical properties:

Composition:

Component: Percent by weight SiO 98.3 B 0 1.39 Na 0 0.025 Al 0 0.30

Surface Area: 200 mF/g.

980 C. The results are shown below. I

What is claimed is:

1. A method for making a low alkali-containing porous glass article having a high thermal stability comprising:

(a) heating a phase-separable alkali-borosilicate glass to a temperature suificient to separate the glass into two phases, one of which is a borate-rich phase and is soluble in an aqueous solution,

(b) a first leaching of the phase-separated glass with water for a time and at a temperature sufi'icient to remove a major portion of the borate-rich phase to form a porous glass high in silica,

(c) a subsequent leaching of the previously leached porous glass with an acid for a time and at a temperature sufficient to remove sufiicient alkali and borate not removed in the first leaching to provide a low alkali-borate containing microporous glass structure having a high thermal stability.

2. The method of claim 1, in which the phase separation is conducted for a period of 1 to 64 hours at a temperature of 420 to 700 C.

3. The method of claim 2 in which the phase separation is conducted for 1 to 8 hours at 420 to 500 C. to produce a porous glass article having pore size diameters ranging from about 50 to 200 Angstrom units.

4. The method of claim 2 in which the phase separation is conducted for 8 to 24 hours at 580 to 650 C. to produce a porous glass article having pore size diameters ranging from about 200 to 1000 Angstrom units.

5. The method of claim 4 in which the water leaching step is conducted with an aqueous solution of metal borate.

6. The method of claim 1, in which the phase-separable alkali-borosilicate glass has the following composition expressed as percentage by weight:

(a) SiO 3035 percent,

(b) B 4055 percent,

(c) R 0, -15 percent, where R is sodium or potassium,

(d) A1 0 0-4 percent.

7. The method of claim 1, in which the first leaching is conducted at a temperature of about 90 to 100 C. for a period of time of about 4 to 24 hours.

8. The method of claim 1, in which the second leaching is with an aqueous solution of mineral acid conducted at a temperature of 80 to 100 C. for at least one-half hour.

9. The method of claim 8, in which the mineral acid has a normality from 0.1 to 3.

10. A method according to claim 1 in which the leachate is passed to a separator to remove at least part of the alkali and borate from the water; the borate and alkali are dried and recycled for use in a subsequent glass melt and the water is recycled for subsequent leaching.

11. A method according to claim 1, in which after the article is leached with mineral acid it is rinsed with de ionized water.

12. A method according to claim 1, in which after the glass is leached to form a porous glass article, the article is shrunk by 5 to percent of its original volume to increase its thermal stability.

13. The method according to claim 12, in which the shrinkage-is accomplished by heat treating the porous glass article at an elevated temperature, but below a tem- '*perature which will completely collapse the pores.

. 14. The method according to claim 13, in which the porous glass article is heat treated at a temperature of about 400 to 1000C. for a period of up to 5 hours.

15. The method according to claim 13 in which after the porous glass article is shrunk, it is treated with a tin solution to deposit tin oxide thereon.

16. An improved method of making a'porous glass article which contains greater than percent by weight silica and which includes the steps of phase separating a borosilicate glass by treatment at an elevated temperature below the miscibility temperature of the glass for a sufficient period of time to form a silica-rich phase and a substantially continuous borate-rich phase, followed by cooling the phase-separated glass, leaching the glass with water to remove a sufficient quantity of the borate-rich phase to form a microporous glass article and separating the microporous glass article from the water leachate, the improvement comprising:

(a) passing the water leachate to a separator,

(b) separating at least part of the borate-rich phase from the water,

(c) passing the Water to unleached phase-separated glass for subsequent leaching,

, (d) drying the borate-rich phase and then passing it to a melting tank which contains essentially only sand,

(e) melting the sand and the borate-rich phase to form a borosilicate glass.

17. The method of claim 16 in Which the borate-rich phase is separated form the water by cooling the leachate to precipitate the borate-rich phase.

18. The method of claim 1 in which the borosilicate glass contains greater than 40 percent B 0 and less than 50 percent SiO 19. In a method for making a high silica porous glass article having high thermal stability, which is formed by removing a borate-rich phase of a phase-separated borosilicate glass composed of an aqueous-soluble borate-rich phase and a substantially aqueous-insoluble silica-rich phase, the improvement comprising:

(a) a first leaching of the phase-separated glass with water for a time and at a temperature sufficient to remove a major portion of the borate-rich phase to form a porous glass high in silica,

(b) a subsequent leaching of the previously water leached porous glass with an acid for a time and at a temperature sufficient to remove sufficient alkali and borate not removed in the first leaching to provide a high silica-containing microporous glass structure having high thermal stability.

20. The method of claim 19 in which the borosilicate glass contains greater than 40 percent B 0 and less than 50 percent SiO' References Cited UNITED STATES PATENTS 2,480,672 8/1949 Plank 65-31 2,215,039 9/1940 Hood et al 65-31 3,630,700 12/1971 Hammel 65-22 3,519,467 7/1970 Plumat et al 117-54 ARTHUR D. KELLOGG, Primary Examiner US. Cl. X.R. 65-31; 117-54 UNITED STATES PATENT OFFICE Page 1 CERTIFICATE OF CORRECTION Patent No, 3,843,341 D d October 22, 1974 Joseph J. Hammel and Ties Allersma It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column5,line 59, cancel "Alternatively" and insert --Alternately.

Column 6, line 47, cancel "20" and insert -200-.

Column 10, line 9, before "and" cancel and insert Column 11, line 21, cancel "diameter" and insert -diameters--.

Column 15, Table II, under Percent by Weight cancel "0.04" and insert --0.02-

Column 16, line 58, after "measuring" insert -theand cancel "in".

Column 17, line 36, after"acid" cancel "lead" and insert --leach-.

Column 17, Table V, after "Cracks" cancel in 50 Beads)" and insert --(in 50 Beads)--.

Column 17, Table V, under Example No. XII, for High temperature exposure at 980C. for 16 hours:

Shrinkage (volume percent) cancel "9.4" and insert --8.4--.

Column 20, under Example number XXII, B 0 cancel "45.57" and insert Columns 19 and 20, under Example numbers XXII, XXIII, XXIV, XXV, and XXVI cancel the heading "Acid leach, N of HCl/ time in hours temp.C."

and insert --Acid leach, N of HCl/time in hours/temp. C.

UNITED STATES PATENT OFFICE Page 2 CERTIFICATE OF CORRECTION Patent No. 5,8 5, 541 Dated OC'bObGI 22, 197

Invent0r(s) Joseph J. Hammel and Ties Allersma It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 21, line 31, cancel "gaphically" and insert --graphically.

Claim 6, line 4, cancel "30-35" and insert -30-50/.

Claim 17, line 2, cancel "form" and insert from-.

a c. I Signed and sealed this 131th say of ixarch l1 l5.

(SEAL) fittest: v C MARSHALL DAR-Ix RUTH C. Z-IASOK Commissioner of Patents Attesting Officer and Trademarks USCOMM-DC 60376-P59 u.s GOVERNMENT rmmmc omcs: 930

FORM P0-1050 (10-69) 

1. A METHOD FOR MAKING A LOW ALKALI-CONTAINING POROUS GLASS ARTICLE HAVING A HIGH THERMAL STABILITY COMPRISING: (A) HEATING A PHASE-SEPARABLE ALKALI-BOROSILICATE GLASSS TO A TEMPERATURE SUFFFICIENT TO SEPARATE THE GLASS INTO TWO PHASES, ONE OF WHICH IS A BORATE-RICH PHASE AND IS SOLUBLE IN AN AQUEOUS SOLUTION, (B) A FIRST LEACHING OF THE PHASE-SEPARATED GLASS WITH WATER FOR A TIME AND AT A TEMPERATURE SUFFICIENT TO REMOVE A MAJOR PORTION OF THE BORATE-RICH PHASE TO FORM A POROUS GLASS HIGH IN SILICA, (C) A SUBSEQUENT LEACHING OF THE PREVIOUSLY LEACHED POROUS GLASS WITH AN ACID FOR A TIME AND AT A TEM- 